Combining process modeling and processing capabilities to scale up the fuel fabrication process.

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Fuel fabrication for next-generation reactors

To minimize the use of highly enriched uranium at research and test reactors around the world, Los Alamos is bringing its expertise to the crucial task of converting reactors to use low enriched uranium (LEU), which has no proliferation appeal. The work is part of a global effort led by the U.S. Department of Energy/NNSA Office of Materials Management and Minimization.

The Los Alamos Fuel Fabrication Program is working on all aspects of developing a high-density fuel: LEU alloyed with 10 weight percent molybdenum (LEU U-10Mo). Once successful, the United States can convert the last of its research reactors.

To optimize and scale-up the fuel fabrication process—from molten metal casting through final fuel plate forming—Los Alamos relies on a combination of

Modeling

Experiment

Advanced characterization methods

In-process sensors

Nondestructive testing

Systems modeling

With capabilities and safety authorization basis for pilot- and laboratory-scale processing, Los Alamos offers a viable alternative process that decreases cost and streamlines production through the following:

Optimizing casting of a monolithic alloy of uranium and 10 wt% molybdenum (U-10Mo) into a billet mold and a triple plate mold

Our value: from pilot to prototype

The Los Alamos Sigma Complex is the only government or industrial site in the United States with the expertise and existing equipment to make this monolithic LEU U-10Mo fuel plate at pilot scale.

The Sigma facility focuses on prototype fabrication and materials research for the nuclear weapons program as well as for threat reduction and homeland security activities.

Los Alamos has a strong track record in

Performing process scale-up

Developing alternative process steps

Using advanced characterization methods to optimize processing steps

Our advanced methods include measuring the crystallographic texture using electron back scatter diffraction (EBSD), and measuring bond strength of thin laminate structures using either controlled buldge testing or microcantilever testing. We use neutron diffraction, x-ray diffraction, the hole drilling method, or the slit method to measure the residual stress.

Bond strength (using controlled bulge testing and microcantilever measurements) at different material interfaces in the fuel to optimize solid-state bonding of aluminum cladding to itself, zirconium to the LEU U-10 wt% Mo, and aluminum cladding to the zirconium diffusion barrier